DTC P3004-803: Power Cable Malfunction: Procedure

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
4. Check if DTCs are output.

   Result

   Result	Proceed to
   P3004-803 only is output.	A
   Any of the following DTCs are also output.	B
   P0A95-123 is also output.	C

   DTC No.	Relevant Diagnosis
   P0A1A-151, 155, 156, 658, 659	Generator Control Module
   P0A1B-164, 193, 512, 661, 786	Drive Motor "A" Control Module
   P0A1D-148	Hybrid Powertrain Control Module
   P0A78-266, 267, 586	Drive Motor "A" Inverter Performance
   P0A94-442	DC/DC Converter Performance
   P0ADB-227	Hybrid Battery Positive Contactor Control Circuit Low
   P0ADC-226	Hybrid Battery Positive Contactor Control Circuit High
   P0ADF-229	Hybrid Battery Negative Contactor Control Circuit Low
   P0AE0-228	Hybrid Battery Negative Contactor Control Circuit High
   P0C76-523	Hybrid Battery System Discharge Time Too Long
   P2511-149	ECM/PCM Power Relay Sensor Circuit Intermittent
   P3004-131, 132	Power Cable Malfunction
   P324E-788	MG-ECU Power Relay Intermittent Circuit
   U0110 (all INF codes)*1	Lost Communication with Drive Motor Control Module "A"

   HINT: 

   • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.
   • P3004-803 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.
5. Turn the power switch off.

B → See step   6 

C → See step   9 

A: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
4. Read and record the DTCs and freeze frame data.
5. Clear DTCs and freeze frame data.
6. Turn the power switch off.

NEXT: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (READY).
3. Ensure the safety of the areas in front and at the back of the vehicle.
4. Move the shift lever to D and depress both the accelerator pedal and brake pedal at the same time.

   HINT: 

   • Depressing both the accelerator pedal and brake pedal at the same time causes the HV battery current to flow and ensures that there is no problem with the high-voltage wiring.
   • Depressing both the accelerator pedal and brake pedal at the same time causes Accelerator and brake depressing in the inappropriate operation and history data to be counted.
5. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
6. Check if DTCs are output.

   Result

   Result	Proceed to
   P3004-803 is output, or no DTCs are output.	A
   Power switch is not turned on (READY) and P3004- 131 is output.	B

   HINT: 

   Because P3004-131 uses 2-trip detection logic, the DTC detection conditions need to be met 2 times.

7. Turn the power switch off.

B → See step   7 

A: Go to next step 

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   NOTE:

   After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

2. Disconnect connector L5 from the power management control ECU.
3. Remove the upper hybrid battery cover sub-assembly. Refer to REMOVAL - Step 19 .
4. Disconnect connector c3 from the hybrid battery junction block assembly.

   HINT: 

   Before disconnecting the connector, check whether it is connected securely to the hybrid battery junction block assembly.

5. Measure the resistance according to the value(s) in the table below.
   Fig 1: Checking Harness And Connector (Power Management Control ECU - Hybrid Battery Junction Block)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   L5-4 (SMRB) - c3-4 (SMRB)	Power switch off	Below 1 Ω
   L5-2 (SMRG) - c3-1 (SMRG)	Power switch off	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *a	Rear view of wire harness connector (to Power Management Control ECU)
   *b	Rear view of wire harness connector (to Hybrid Battery Junction Block Assembly)

6. Connect hybrid battery junction block assembly connector.
7. Install the upper hybrid battery cover sub-assembly.
8. Connect the power management control ECU connector.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   8